Kyosho Blizzard FR Dual 540 Transmission

Last crawled date: 4 years, 3 months ago

Kyosho Blizzard FR Dual 540 Motor Transmission
* Works with SR, FR and FR 2.0 versions for sure, maybe others **
NOT compatible with the standard plow lifting mechanism
Compatible with my modded plow : https://www.thingiverse.com/thing:4097561
The only cutting required is the battery "box", the rest can be put back in if you ever need to.
Both motors run in the same direction, meaning you CAN use timed motors and both will run forward when going forward. This is why one side has 1 additional gear.
I made FR and RR variant depending if your transmission is at the front or the rear. Standard is at the front but you can reverse the body to get the transmission at the rear (I prefer it at the rear myself, it counter-balances my custom plow weight nicely)
The FR and RR (front or rear) variant is made for Counter-Clockwise turning motors. So if you have Clockwise motors and your gearbox is at the rear, you actually want the FR variant.(Most stock brushed motors are CCW)
The gears go from MOD1.5 to MOD1 to 32Pitch, should be plenty strong for brushed motors, use Brushless at your own risk.
Non-printed parts required :
(10x) 3x8x4 bearings
(2x) 5x11x4 bearings
(4x) 5x10x4 bearings
(4x) M3x30 bolts (Button or Socket head)
(1x) M3x30 bolt ("Flat" (Conical) head)
(5x) M3x8 or M3x10 bolts ("Flat" (Conical) head)
(2x) M3x25 bolts (Button head)
(4x) M3x10 bolts
(2x) M3x8 bolts
(7x) M3 nuts (Nylock recommended)
(2x) M3 nuts (Regular, for the locking collars)
(10x) M3 washers
(2x) 11 to 14 Teeth 32 Pitch Pinion gears for your motors
Notes :
35T Motors give a good mix of speed and torque per my testings.
Original Ratio is 5.06:1 , this modified one is 4.6:1 so a little faster than stock.
Use the washers to space each gear that has a bearing, 2 washers per gear.
Don't overtighten the 5x gear bolts, the gears need to be loose.
Make sure there is no gap in the gear teeth when slicing/printing, play with your line width until you get a complete fill, otherwise they will probably fail quickly.
Using PETG or better yet Nylon for the gears is suggested, although i made mine in eSun PLA+ and they work. Use some lubricant on the gears for best longevity and less noise. Make sure your lubricant doesn't affect your plastic type (Regular grease can make some plastics brittle, I used "Fluid Film" but you can also use Lithium based grease for plastic).
Instructions :
Remove stock transmission, remove cross pins on the shaft.
Snip off the battery "box" that is in the way of the motor
Remove all the plow mechanism including the chrome metal tube at the front
Remove both shaft from their support part, remove the one bushing per side and replace with the 2x 5x10x4 bearings on each side.
Reinsert one shaft completely and the other only part-way.
Insert the stock locking collars into the output gears, remove the stock locking screw from the collar and use 2x M3x10 bolts instead to lock the gear on the collar and then lock the collar on the shaft
Assemble both gearboxes using the screws, nuts, washers, motors and 5x11x4 bearings
Slide the first gearbox onto the fully inserted shaft, lock it in place using the collars (the one inside the output gear and the printed one)
Insert the second shaft fully while also inserting the remaining gearbox on it and the printed locking collar. Lock everything in place.
Make sure everything's pretty square and mark the holes for drilling through the floor pan on the underside and on the front/rear angled part. Screw everything in place, make sure the gears turn easily